Electric Conversion, increasing ground clearance

jpanichella · February 18th, 2016, 07:27 PM

Hey guys,

A little background on my project. It's a 2000 Ninja 250, I gusseted the frame and replaced the engine with a battery pack and electric motor that produces around 35 HP. The battery pack is from a salvaged Nissan Leaf. The bike's really fun, but I'm a little worried about ground clearance. I'm just exploring my options if it becomes a concern. Here's a few pictures of the bike.

When it's on it's side stand, the leaning corner of the battery pack is 6" off the ground. I was thinking about raising the bike, I did some research and found a place that does custom fork tubes at any length. I was thinking about maybe getting 1 or 2 inches over stock, and raising the rear end as well to keep the geometry the same. Will this change the rideability of the bike in any significant way? What do you guys think?

Thanks for your help.

csmith12 · February 19th, 2016, 03:36 AM

Welcome Jon!

Electric car engine on a bike!

Sounds like a cool project but your pics are not showing up for me. Can you check the privacy or share settings on them in your google account so we all can see? I am really interested in how you mounted that all together.

In general... I would be worried about ground clearance via suspension as well. The pregen ninja's aren't really known for their spectacular springs. It sounds like you know this already but maybe you can just respring the stock tubes and totally replace the rear shock to something more suitable that would require much less customization and be a lot cheaper.

Ghostt · February 19th, 2016, 08:10 AM

No pics?

Why are you worried about ground clearance? Are you using it off road?

I agree about the PreGen suspension being soft, cheap solution is to get the spring, and shock from a NewGen.

Alex · February 19th, 2016, 08:21 AM

Pics seem to be in a protected google account; the OP is likely the only one that can view them.

HoneyBadgerRy · February 19th, 2016, 09:23 AM

Quote:

Originally Posted by Ghostt

No pics?

Why are you worried about ground clearance? Are you using it off road?

I agree about the PreGen suspension being soft, cheap solution is to get the spring, and shock from a NewGen.

There is a thread over on Ex500's about cutting the stock springs to stiffen them up, and it had a formula about the current spring rating, your weight, and how much to cut off. Obviously you can only cut off so much without getting coil bind, however I has able to easily modify the stock ninja 250 springs to be rated perfectly for my 130-140 lbs and it was much cheaper than buying newgen suspension, or buying springs. As for the rear, a newgen shock is a ok cheap option, but I would opt for something with some adjustability.

I'm not sure why OP is worried about ground clearance, but If he is planning on taking the bike in rough off road like conditions, then maybe he would be better off buying a used MX shock.

Ghostt · February 19th, 2016, 11:28 AM

I cut mine too, but I had a pair of 1st Gen EX springs laying around, which are about .55kg and 20.5" in length, as opposed to PreGen @ .44, 18" in length The NewGen is about .65, less cut if you need to increase.

I had to cut about 5.5" off the EX, , which raised them up to about .82, 15" length.

The rear shock in a PreGen is crap, at least the NewGen is better for a heavy rider, about 200lbs, and you can adjust the preload to set the static sag, both modifications are easy enough to do as it's just replacing, no modifications necessary, unless your cutting the springs, and you can find them cheap on eBay.

jpanichella · February 19th, 2016, 08:05 PM

Hey guys, sorry about the pictures. Do these work?

csmith12 · February 19th, 2016, 08:07 PM

Yes sir, those work just fine. Cool mods!!!! Spring it up as you see fit, you shouldn't have a ground clearance problem after that unless you're riding it on the track.

Well done!

Ghostt · February 19th, 2016, 08:09 PM

Now that is just awesome, well done sir, well done.

HoneyBadgerRy · February 19th, 2016, 08:32 PM

That looks cool. The only thing I can say is you should bondo the gas tank to hide the bolt holes, and make the ridge calmer. (Make it look more factory)

jpanichella · February 19th, 2016, 08:59 PM

Quote:

Originally Posted by HoneyBadgerRy

That looks cool. The only thing I can say is you should bondo the gas tank to hide the bolt holes, and make the ridge calmer. (Make it look more factory)

Thanks for the kind words guys! The tank is the last big task, that and finishing the 12 volt system. Here's a timelapse of the build and a ride by.

Link to original page on YouTube.

crazymadbastard · February 20th, 2016, 09:29 AM

Hotness!

Mohawk · February 26th, 2016, 04:16 PM

Sweet, what motor & controller did you use ? I thought about doing this to a bike, but batteries are expensive. So recycling a wrecked car set is a great idea.

jpanichella · February 27th, 2016, 11:22 AM

Quote:

Originally Posted by Mohawk

Sweet, what motor & controller did you use ? I thought about doing this to a bike, but batteries are expensive. So recycling a wrecked car set is a great idea.

I used this motor and controller package:

http://www.evdrives.com/product_p/ck-1003.htm

You can source batteries locally, or this company recycles hybrid cars and sells the batteries individually. I used 10 of these modules.

http://hybridautocenter.com/HAC4/ind...ule&Itemid=605

crazymadbastard · February 27th, 2016, 12:20 PM

Quote:

Originally Posted by jpanichella

I used this motor and controller package:

http://www.evdrives.com/product_p/ck-1003.htm

You can source batteries locally, or this company recycles hybrid cars and sells the batteries individually. I used 10 of these modules.

http://hybridautocenter.com/HAC4/ind...ule&Itemid=605

what is the expected range? and which charger is used?

jpanichella · February 28th, 2016, 11:25 PM

Quote:

Originally Posted by crazymadbastard

what is the expected range? and which charger is used?

They're LED drivers made by meanwell, I'm doing a writeup and will include some more info.

SLOWn60 · February 29th, 2016, 04:40 AM

Quote:

Originally Posted by jpanichella

I'm a little worried about ground clearance.

Mount the battery horizontally? Boxer style!

Excellent project! Well done, Sir!

MrAtom · February 29th, 2016, 04:51 AM

What does it top out at? 0-60 times? Does it like to wheelie? How far can you travel on one charge? So many questions!

Mohawk · February 29th, 2016, 06:08 AM

Not sure of the dimensions, but it looks like there would be room to mount the battery turned through 90degrees, so what is currently across the frame would be front to rear.

If you are worried about front wheel clearance, just put bike in choc's then remove the handlebars, lossen top clamps & remove fork caps, let forks colapse to full compression, theen see how much space you have left !

jpanichella · November 2nd, 2017, 09:07 PM

Don't have enough posts for a classified thread, but wanted to let you know that the bike is for sale. Asking for $4900.

I finished everything up and it runs perfect. I also stiffened up the front end so ground clearance is a nonissue.

For sale is my custom built electric Ninja 250. Fully street legal and ready to ride. The last thing that needs finished is the gas tank, it's primed and ready for the new owner to put their mark on this bike.

Here's the basic specs:

Top Speed: 87 mph (that's the fastest I've gone, but I ran out of straight road)
Range: About 50 miles if you're driving in town
Charge Time: About 2.5 hours from your standard wall socket
Brand new Pirelli tires
Powdercoated Frame, Wheels and Hardware
New Brake Pads and stainless brake line
LED Headlight/Tail Light/Turn Signals

I started with a Ninja 250 frame, and built the bike around a battery pack borrowed from a Nissan leaf. Then I installed a battery management system that shuts off the chargers when the batteries are full, and gives me a warning when the batteries are dangerously low. The motor is a very commonly used EV motor by Motenery. The controller is an Alltrax and can be programmed via USB cable (custom throttle curves, etc.)

It's a great commuter vehicle. Always reliable, smooth, you won't smell like gas when you get there. You don't need to shift gears, it's just twist and go, like a scooter. Costs pennies to fill up when charged during off peak hours. I've documented the build below:

http://www.dotheton.com/forum/index.php?topic=64772.0

And of course I'll help you understand how it works and include all the documentation and wiring diagrams. Let me know if you have any questions or wanted to give it a try. I'm selling it because I want to try and convert a full sized vehicle next, it's a really fun hobby.

DannoXYZ · November 2nd, 2017, 10:29 PM

Very interesting. What's the bike weigh?

jpanichella · November 2nd, 2017, 11:50 PM

I haven't weighed it, but it feels like like it's sub 250 pounds. Most people who ride it immediately comment on how light it feels.

greenaero · November 4th, 2017, 06:45 AM

very nice work!

psych0hans · November 4th, 2017, 07:04 AM

Good luck! I'm going to attempt something similar and make a track bike out of a duke 390 rolling chassis.

NinjaBraap · November 9th, 2017, 05:56 PM

Now paint it black and wear bat ears! hahaha that's got to be one of the best 250 conversions ever!

February 18th, 2016, 07:27 PM	#1
jpanichella ninjette.org member Name: Jon Location: Oceanside, CA Join Date: Feb 2016 Motorcycle(s): Electric Ninja 250 Posts: 12	Electric Conversion, increasing ground clearance Hey guys, A little background on my project. It's a 2000 Ninja 250, I gusseted the frame and replaced the engine with a battery pack and electric motor that produces around 35 HP. The battery pack is from a salvaged Nissan Leaf. The bike's really fun, but I'm a little worried about ground clearance. I'm just exploring my options if it becomes a concern. Here's a few pictures of the bike. When it's on it's side stand, the leaning corner of the battery pack is 6" off the ground. I was thinking about raising the bike, I did some research and found a place that does custom fork tubes at any length. I was thinking about maybe getting 1 or 2 inches over stock, and raising the rear end as well to keep the geometry the same. Will this change the rideability of the bike in any significant way? What do you guys think? Thanks for your help.

February 19th, 2016, 03:36 AM	#2
csmith12 The Corner Whisperer Name: Chris (aka Reactor) Location: Northern KY Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much. MOTY 2015, MOTM - Nov '12, Nov '13	Welcome Jon! Electric car engine on a bike! Sounds like a cool project but your pics are not showing up for me. Can you check the privacy or share settings on them in your google account so we all can see? I am really interested in how you mounted that all together. In general... I would be worried about ground clearance via suspension as well. The pregen ninja's aren't really known for their spectacular springs. It sounds like you know this already but maybe you can just respring the stock tubes and totally replace the rear shock to something more suitable that would require much less customization and be a lot cheaper. __________________________________________________ Goal: Shake A Million Hands \| Look through the corners \| Track Day Prep \| Closest track? \| The Mid-Ohio School

February 19th, 2016, 08:10 AM	#3
Ghostt in your machine Name: Scott Location: Summer Shade, Ky. Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot. Blog Entries: 25 MOTM - Jun '17, May '16, Mar '15	No pics? Why are you worried about ground clearance? Are you using it off road? I agree about the PreGen suspension being soft, cheap solution is to get the spring, and shock from a NewGen. __________________________________________________ *violente et ignorantia* ZX-2R BLOG *Twitter and Instagram = Ghostt_Scott* *I'm not here to change your mind, just to inform.*

February 19th, 2016, 08:21 AM	#4
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	Pics seem to be in a protected google account; the OP is likely the only one that can view them. __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

February 19th, 2016, 11:28 AM	#6
Ghostt in your machine Name: Scott Location: Summer Shade, Ky. Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot. Blog Entries: 25 MOTM - Jun '17, May '16, Mar '15	I cut mine too, but I had a pair of 1st Gen EX springs laying around, which are about .55kg and 20.5" in length, as opposed to PreGen @ .44, 18" in length The NewGen is about .65, less cut if you need to increase. I had to cut about 5.5" off the EX, , which raised them up to about .82, 15" length. The rear shock in a PreGen is crap, at least the NewGen is better for a heavy rider, about 200lbs, and you can adjust the preload to set the static sag, both modifications are easy enough to do as it's just replacing, no modifications necessary, unless your cutting the springs, and you can find them cheap on eBay. __________________________________________________ *violente et ignorantia* ZX-2R BLOG *Twitter and Instagram = Ghostt_Scott* *I'm not here to change your mind, just to inform.*
	1 out of 1 members found this post helpful.

February 19th, 2016, 08:05 PM	#7
jpanichella ninjette.org member Name: Jon Location: Oceanside, CA Join Date: Feb 2016 Motorcycle(s): Electric Ninja 250 Posts: 12	Hey guys, sorry about the pictures. Do these work?
	1 out of 1 members found this post helpful.

February 19th, 2016, 08:07 PM	#8
csmith12 The Corner Whisperer Name: Chris (aka Reactor) Location: Northern KY Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much. MOTY 2015, MOTM - Nov '12, Nov '13	Yes sir, those work just fine. Cool mods!!!! Spring it up as you see fit, you shouldn't have a ground clearance problem after that unless you're riding it on the track. Well done! __________________________________________________ Goal: Shake A Million Hands \| Look through the corners \| Track Day Prep \| Closest track? \| The Mid-Ohio School

February 19th, 2016, 08:09 PM	#9
Ghostt in your machine Name: Scott Location: Summer Shade, Ky. Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot. Blog Entries: 25 MOTM - Jun '17, May '16, Mar '15	Now that is just awesome, well done sir, well done. __________________________________________________ *violente et ignorantia* ZX-2R BLOG *Twitter and Instagram = Ghostt_Scott* *I'm not here to change your mind, just to inform.*

February 19th, 2016, 08:32 PM	#10
HoneyBadgerRy ninjette.org certified postwhore Name: Ryan Location: Beaufort SC Join Date: Aug 2015 Motorcycle(s): 05 Ninja 250, 04 KTM 625 SMC, 01 Xc250 Posts: A lot. Blog Entries: 3	That looks cool. The only thing I can say is you should bondo the gas tank to hide the bolt holes, and make the ridge calmer. (Make it look more factory) __________________________________________________ Because Unregistered sucks at riding.

February 20th, 2016, 09:29 AM	#12
crazymadbastard I'm crazy,your excuse is? Name: Winston Location: Connecticut Join Date: May 2013 Motorcycle(s): 250 2007 ninja Posts: A lot.	Hotness! __________________________________________________ My Cafe Racer Build My intro post

February 26th, 2016, 04:16 PM	#13
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 478	Sweet, what motor & controller did you use ? I thought about doing this to a bike, but batteries are expensive. So recycling a wrecked car set is a great idea.

February 29th, 2016, 04:51 AM	#18
MrAtom . Name: . Location: . Join Date: Aug 2014 Motorcycle(s): . Posts: A lot. MOTM - July '15	What does it top out at? 0-60 times? Does it like to wheelie? How far can you travel on one charge? So many questions!

February 29th, 2016, 06:08 AM	#19
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 478	Not sure of the dimensions, but it looks like there would be room to mount the battery turned through 90degrees, so what is currently across the frame would be front to rear. If you are worried about front wheel clearance, just put bike in choc's then remove the handlebars, lossen top clamps & remove fork caps, let forks colapse to full compression, theen see how much space you have left !

November 2nd, 2017, 09:07 PM	#20
jpanichella ninjette.org member Name: Jon Location: Oceanside, CA Join Date: Feb 2016 Motorcycle(s): Electric Ninja 250 Posts: 12	Don't have enough posts for a classified thread, but wanted to let you know that the bike is for sale. Asking for $4900. I finished everything up and it runs perfect. I also stiffened up the front end so ground clearance is a nonissue. For sale is my custom built electric Ninja 250. Fully street legal and ready to ride. The last thing that needs finished is the gas tank, it's primed and ready for the new owner to put their mark on this bike. Here's the basic specs: Top Speed: 87 mph (that's the fastest I've gone, but I ran out of straight road) Range: About 50 miles if you're driving in town Charge Time: About 2.5 hours from your standard wall socket Brand new Pirelli tires Powdercoated Frame, Wheels and Hardware New Brake Pads and stainless brake line LED Headlight/Tail Light/Turn Signals I started with a Ninja 250 frame, and built the bike around a battery pack borrowed from a Nissan leaf. Then I installed a battery management system that shuts off the chargers when the batteries are full, and gives me a warning when the batteries are dangerously low. The motor is a very commonly used EV motor by Motenery. The controller is an Alltrax and can be programmed via USB cable (custom throttle curves, etc.) It's a great commuter vehicle. Always reliable, smooth, you won't smell like gas when you get there. You don't need to shift gears, it's just twist and go, like a scooter. Costs pennies to fill up when charged during off peak hours. I've documented the build below: http://www.dotheton.com/forum/index.php?topic=64772.0 And of course I'll help you understand how it works and include all the documentation and wiring diagrams. Let me know if you have any questions or wanted to give it a try. I'm selling it because I want to try and convert a full sized vehicle next, it's a really fun hobby.

November 2nd, 2017, 10:29 PM	#21
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Very interesting. What's the bike weigh?

November 2nd, 2017, 11:50 PM	#22
jpanichella ninjette.org member Name: Jon Location: Oceanside, CA Join Date: Feb 2016 Motorcycle(s): Electric Ninja 250 Posts: 12	I haven't weighed it, but it feels like like it's sub 250 pounds. Most people who ride it immediately comment on how light it feels.

November 4th, 2017, 06:45 AM	#23
greenaero Motorcycle Hypermiler Name: Vic Location: Livermore CA Join Date: Jan 2012 Motorcycle(s): 1999 & 2005 Kawasaki Ninja 250R's Posts: A lot.	very nice work! __________________________________________________ 235 MPG Hypermotorcycling to a better tomorrow

November 4th, 2017, 07:04 AM	#24
psych0hans ninjette.org certified postwhore Name: Hansveer Location: Bombay, India Join Date: Jan 2012 Motorcycle(s): Ninja 250r - Track whore, Ninja 300 - SOLD, KTM RC390 - Orange Hulk, Ducati 899 Panigale - Red Devil. Posts: A lot.	Good luck! I'm going to attempt something similar and make a track bike out of a duke 390 rolling chassis. __________________________________________________ GETTING BACK INTO RIDING? Read this.

November 9th, 2017, 05:56 PM	#25
NinjaBraap NinjaBraap Name: Tom Location: Long Beach, California Join Date: Dec 2016 Motorcycle(s): 06 Ninja 636, 2016 Yamaha R3 (Street/Track), 2019 Ninja 400 Project Racebike Posts: 175 Blog Entries: 2	Now paint it black and wear bat ears! hahaha that's got to be one of the best 250 conversions ever! __________________________________________________ Racer, Mechanic, Enthusiast. Vendor for Norton Motorsports Subscribe to my Instagram and YouTube: Instagram YouTube

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